Cast excavator bucket

ABSTRACT

A cast iron excavator bucket is provided that includes a first side wall, a second side wall, and a center wall interconnecting the first side wall and second side wall to form an inner cavity for receiving excavated materials, wherein the first side wall, the second side wall, and the center wall are integrally cast exclusively from iron.

FIELD OF THE INVENTION

This invention relates generally to excavation equipment.

BACKGROUND

Excavation equipment is generally used to extract materials and can alsobe used to supply materials. Various types of excavation equipmentexist, with at least some utilizing an excavator bucket that includes amaterial cavity and teeth extending from the bucket for digging andbreaking up materials.

SUMMARY OF THE INVENTION

In at least some embodiments, a cast iron excavator bucket is providedthat includes a first side wall, a second side wall, and a center wallinterconnecting the first side wall and second side wall to form aninner cavity for receiving excavated materials, wherein the first sidewall, the second side wall, and the center wall are integrally castusing only a casting material derived exclusively from iron ingot.

In at least some other embodiments, a method of casting an ironexcavator bucket is provided that includes: forming a bucket-shaped sandmold including a first mold side wall, a second mold side wall, and acenter mold wall interconnecting the first mold side wall and the secondmold side wall to form a mold inner cavity; providing a molten castingmaterial made exclusively from iron ingot; pouring the molten castingmaterial into the bucket-shaped sand mold; allowing the molten castingmaterial to cool; and removing the cooled casting material from thebucket-shaped sand mold.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are disclosed with reference to theaccompanying drawings and are for illustrative purposes only. Theinvention is not limited in its application to the details ofconstruction or the arrangement of the components illustrated in thedrawings. The invention is capable of other embodiments or of beingpracticed or carried out in other various ways. In the drawings:

FIG. 1 is a front perspective view of an exemplary embodiment of a castiron excavator bucket;

FIG. 2 is a rear perspective view of the bucket of FIG. 1 ;

FIG. 3 is a top view of the bucket of FIG. 1 ;

FIG. 4 is a rear view of the bucket of FIG. 1 ;

FIG. 5 is a front view of the bucket of FIG. 1 ;

FIG. 6 is a bottom view of the bucket of FIG. 1 ;

FIG. 7 is a first side view of the bucket of FIG. 1 ;

FIG. 8 is a second side view of the bucket of FIG. 1 ;

FIG. 9 is a top perspective view of the bucket of FIG. 1 with aplurality of teeth coupled therewith;

FIG. 10 is a bottom perspective view of the bucket and teeth of FIG. 9 ;

FIG. 11 is an exploded view of the bucket and teeth of FIG. 9 ;

FIG. 12 is a bottom perspective view of a tooth shank;

FIG. 13 is a perspective side view of the bucket of FIG. 1 with thetooth shank of FIG. 12 ; and

FIG. 14 is a perspective view of a backhoe with the bucket of FIG. 9coupled therewith.

DETAILED DESCRIPTION

Referring to FIGS. 1-10 , a cast iron excavator bucket 10 is shown inaccordance with one exemplary embodiment of the invention. The bucket 10includes integrally formed first side wall 12, second side wall 14, andcenter wall 16 interconnecting the first side wall 12 and second sidewall 14. The center wall 16 includes a front portion 18, a bottomportion 20 and a rear portion 22. In at least some embodiments, thecenter wall 16 is substantially curved. The first side wall 12, secondside wall 14, and center wall 16 form an inner cavity 24 configured forreceiving, transporting, and distributing materials, such as soil, rock,etc. The inner cavity 24 can be formed in various shapes and sizes. Thebucket 10 is configured to be coupled to and actuated by a machine inorder to manipulate materials (e.g., excavate, etc.), one such exemplarymachine can be a backhoe 25, such as shown in FIG. 14 , which isconfigured to be coupled with a compact utility tractor.

To facilitate coupling and actuation, the bucket 10 includes one or morearm mounts 26 secured to or formed integrally therewith, wherein the armmounts 26 can be sized and shaped to custom specifications or to conformto general standards for interfacing with known machines. In at leastsome embodiments, a plurality of tooth engagement portions 28 are formedin the front portion 18 of the center wall 16 for respectively receivinga plurality of teeth 30 secured thereto using a plurality of fasteners,such as bolts 32 and nuts 34 (see FIGS. 9-12 ), while in otherembodiments, the teeth 30 can be integrally cast with the center wall 16and not require a mechanical means (e.g. fasteners, welding, etc.) tosecure the teeth 30. The tooth engagement portions 28 can in someembodiments include thicker or thinner (i.e., reinforced less or more)portions of the center wall 16 relative to other portions of the centerwall 16. Further, in another embodiment the bucket 10 can include aplurality of tooth shanks 36 integrally cast with the front portion 18of the center wall 16, wherein the tooth shanks 36 are configured toreceive and secure a plurality of respective teeth sized and shaped forsecurement to the tooth shanks 36.

In at least some embodiments, the first side wall 12 and the second sidewall 14 taper inwards (angle inward as a result of the center wall 16being narrower along the bottom portion) as they extend towards thebottom portion 20 of the center wall 16, as best seen in FIGS. 3 and 6 ,wherein the distance D1 between the first side wall 12 and the secondside wall 14 about a top portion 40 of the bucket 10 is greater than thedistance D2 about the bottom portion 20 of the bucket 10. Further, in atleast some embodiments, the first side wall 12 and the second side wall14 taper inwards as they extend from the rear portion 22 to the frontportion 18, as best seen in FIG. 3 , wherein the distance D3 between thefirst side wall 12 and the second side wall 14 at the rear portion 22 ofthe bucket 10 is greater than a distance D4 between the first side wall12 and the second side wall 14 at the front portion 18 of the bucket 10.

The bucket 10 can be formed using various methods. In at least someembodiments, the bucket 10 is formed using a method that includes thesteps of: (i) forming a bucket-shaped sand mold including a first moldside wall, a second mold side wall, and a center mold wallinterconnecting the first side wall and second side wall to form a moldinner cavity; (ii) providing a molten casting material made entirelyfrom iron ingot; (iii) pouring the molten casting material into the sandmold; allowing the molten casting material to cool; (iv) and removingthe cooled casting material from the sand mold.

In at least some embodiments, the bucket 10 is cast from a materialcomprised entirely of iron. As it is well known that raw iron ingotincludes nominal amounts of unavoidable impurities, it shall beunderstood that “comprised entirely of iron” or “material derivedexclusively from iron ingot” or “exclusively from iron” is intended toinclude incidental impurities provided in the raw iron ingot, butexclude the intentional addition of other separate elements, such asaluminum, silicon, chromium, manganese, etc., to form a desired alloy. Atypical composition for a bucket comprised entirely of cast ductileiron, as described herein, would include the use of a molten iron thatincludes the following exemplary levels of impurities: Carbon—3.65%;Silicon—2.50%; Sulfur—Copper—0.50%; and Manganese—0.25%.

The casting of large buckets using a steel alloy that includesintentionally added elements is known, but the use of a such steel alloyhas several limitations. More particularly, commonly used steel alloyshave a higher solidification temperature due to the additionalintentionally added elements. Higher solidification temperatures withlarger bucket casting sizes, which have thicker cast sections, workssatisfactory, but when producing smaller bucket castings that typicallyinclude thin cast sections, such alloys are problematic. With smallerbucket size castings, such as those used for typical 9 inch, 12 inch, 16inch, and 24 inch bucket sizes, as commonly used in the compact utilitytractor market, when additional intentionally added elements areincluded, the thin cast sections (e.g., side walls, etc.) do not staymolten along with the thicker cast sections (e.g., the center wall,etc.) as they cool faster, resulting in undesirably weak joints betweenvarious sections. Having all sections of the cast bucket coolsubstantially simultaneously results in a strong and durable bucket,which is why steel alloys can be satisfactorily used for larger bucketsizes where all wall sections are comparatively thick, while smallerbuckets sizes with thin walls must use separately cast steel platesections that are welded together to achieve the desired strength.

The overall dimensions and shapes of the aforementioned typical smallerbuckets and castings can vary to some degree based on the manufactureand intended use of the bucket, although in at least some embodiments,the cast iron excavator bucket 10 first side wall 12 and second sidewall 14 can be formed with a thickness of about 3/16 inch to about ⅜inch or even thinner, with other thicknesses found in furtherembodiments.

As known small bucket sizes utilize several plates welded together, suchbuckets lack many of the features found in larger cast buckets. Moreparticularly, casting the bucket 10 allows for integral design featuresthat will strengthen typical stress areas, such as where side walls meetthe bottom, front, and rear portions. These design features can includefor example, curves, bevels, reinforcements, webs, tapers, etc. Further,as mentioned above, the ability to cast a smaller bucket 10 allows forother options such as integrally forming tooth engagement portions 28,teeth 30, tooth shanks 36, etc. The tooth engagement portions 28 caneasily be made thicker or thinner (i.e., reinforced less or more)relative to other portions.

In addition to the disclosed shapes and sizes, all the aforementionedcomponents, can vary to include numerous adaptations. The use of theterm “plurality” in the description or claims shall be understood toinclude “one or more.” While the invention is particularly useful foruse with excavator buckets, other applications are possible andreferences to use with excavator machines should not be deemed to limitthe application of the invention. Rather, the invention may beadvantageously adapted for use where similar performance capabilitiesand characteristics are desired, and that such modifications may be madeby one of skill in the art of the invention without departing from thespirit or intent of the invention and therefore, the invention is to betaken as including all reasonable equivalents to the subject matter.

What is claimed is:
 1. A cast iron excavator bucket comprising: a firstside wall; a second side wall; and a center wall interconnecting thefirst side wall and the second side wall to form an inner cavity forreceiving excavated materials, wherein the first side wall, the secondside wall, and the center wall are integrally cast using only a castingmaterial derived exclusively from iron ingot.
 2. The bucket of claim 1,wherein the first side wall and the second side wall both taper inwardsas they extend towards a bottom portion of the center wall.
 3. Thebucket of claim 2, further comprising a plurality of arm mountscomprised entirely of iron and formed integrally with at least one ofthe center wall, the first side wall, and the second side wall, forcoupling with a machine.
 4. The bucket of claim 2, further comprising aplurality of arm mounts secured to at least one of the center wall, thefirst side wall, and the second side wall, for coupling with a machine.5. The bucket of claim 4, further comprising a plurality of toothengagement portions formed in the center wall for receiving and securingrespective teeth using a plurality of fasteners.
 6. The bucket of claim5, wherein the first side wall and the second side wall have a thicknessof about 3/16 inch to about ⅜ inch.
 7. The bucket of claim 3, furthercomprising a plurality of tooth shanks integrally formed in a frontportion of the center wall, wherein the plurality of tooth shanks areconfigured to receivably secure respectively teeth.
 8. The bucket ofclaim 3, further comprising a plurality of teeth integrally cast in thefront portion of the center wall.
 9. A method of casting an ironexcavator bucket comprising: forming a bucket-shaped sand mold includinga first mold side wall, a second mold side wall, and a center mold wallinterconnecting the first mold side wall and the second mold side wallto form a mold inner cavity; providing a molten casting material madeexclusively from iron ingot; pouring the molten casting material intothe bucket-shaped sand mold; allowing the molten casting material tocool; and removing the cooled casting material from the bucket-shapedsand mold.